Appliance control module with in-molded electronics

ABSTRACT

A control module of an appliance is provided. The control module includes a housing having a film integrally molded onto an outer surface of the housing. The film includes conductive ink embedded in the film. A header on the film is in electrical communication with the conductive ink embedded in the film. The control module also includes a printed circuit board mounted within the housing proximate an inner surface of the housing. The film is connected to the printed circuit board via the header. With this connection, the printed circuit board is in operative communication with the conductive ink embedded in the film.

FIELD

The present subject matter relates generally to control modules forappliances, such as control modules including at least one in-moldedelectronic component which can be directly connected to a printedcircuit board.

BACKGROUND

Appliances generally include a control panel having a plurality ofbuttons, keys, or other input devices. Utilizing the control panel, anappliance user can input control commands to the appliance and operatethe appliance. Certain control panels include a control module having ahousing with a film material in-molded in the housing. The in-moldedfilm may have printed material on the film. For example, the in-moldedfilm may include one or more electronic components formed by printingcircuitry onto the film with conductive inks. Such in-molded electronicscan decrease an overall size of the control panel and reduce the sizeand/or number of circuit boards required.

However, such in-molded electronics are typically connected toassociated circuit boards with additional intervening connectionelements. For example, a cable such as a ribbon cable may be used toconnect the in-molded electronics to the circuit board. Such connectionsmay increase the overall size of the control panel and may introduceadditional potential failure points. For example, the connectors maywork loose over time due to vibrations.

Accordingly, a control module for an appliance that includes in-moldedelectronics with improved features for connecting the in-moldedelectronics to a circuit board would be useful.

BRIEF DESCRIPTION

Aspects and advantages of the technology will be set forth in part inthe following description, or may be apparent from the description, ormay be learned through practice of the technology.

In an exemplary embodiment, an appliance defining a vertical direction,a lateral direction and a transverse direction that are mutuallyperpendicular to one another is provided. The appliance includes acabinet extending between a top and a bottom along the verticaldirection, between a left side and a right side along the lateraldirection, and between a front and a rear along the transversedirection. The appliance also includes a control module disposed in thecabinet. The control module includes a housing having a film integrallymolded onto an outer surface of the housing. The film includesconductive ink embedded in the film. A header on the film is inelectrical communication with the conductive ink embedded in the film.The control module also includes a printed circuit board mounted withinthe housing proximate an inner surface of the housing. The film isconnected to the printed circuit board via the header. With thisconnection, the printed circuit board is in operative communication withthe conductive ink embedded in the film.

In another exemplary embodiment, a control module of an appliance isprovided. The control module includes a housing having a film integrallymolded onto an outer surface of the housing. The film includesconductive ink embedded in the film. A header on the film is inelectrical communication with the conductive ink embedded in the film.The control module also includes a printed circuit board mounted withinthe housing proximate an inner surface of the housing. The film isconnected to the printed circuit board via the header. With thisconnection, the printed circuit board is in operative communication withthe conductive ink embedded in the film.

These and other features, aspects and advantages of the presenttechnology will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the technology and, together with the description, serveto explain the principles of the technology.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present technology, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures.

FIG. 1 provides a perspective view of a washing machine appliance as mayincorporate a user interface in accordance with at least one embodimentof the present subject matter.

FIG. 2 provides a perspective view of components of a control modulewhich may be incorporated into an appliance such as the exemplarywashing machine appliance of FIG. 1.

FIG. 3 provides a side section view of the components of FIG. 2according to one or more embodiments of the present subject matter.

FIG. 4 provides a side section view of selected components of FIG. 2according to one or more embodiments of the present subject matter.

FIG. 5 provides a side section view of selected components of FIG. 2according to one or more embodiments of the present subject matter.

FIG. 6 provides a side section view of selected components of FIG. 2according to one or more embodiments of the present subject matter.

FIG. 7 provides a side section view of selected components of FIG. 2according to one or more additional embodiments of the present subjectmatter.

FIG. 8 provides a side section view of selected components of FIG. 2according to one or more additional embodiments of the present subjectmatter.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the technology,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the technology, notlimitation of the technology. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present technology without departing from the scope or spirit ofthe technology. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present technologycovers such modifications and variations as come within the scope of theappended claims and their equivalents.

As used herein, terms of approximation such as “generally,” “about,” or“approximately” include values within ten percent greater or less thanthe stated value. When used in the context of an angle or direction,such terms include within ten degrees greater or less than the statedangle or direction, e.g., “generally vertical” includes forming an angleof up to ten degrees in any direction, e.g., clockwise orcounterclockwise, with the vertical direction V.

FIG. 1 provides a perspective view of an appliance 100 according to anexemplary embodiment of the present subject matter. In the illustratedexample, the appliance 100 is a washing machine appliance. In otherexamples, the appliance 100 may be a dryer appliance, a refrigerator, anoven, e.g., a range appliance or a microwave oven, a dishwasher, or anyother suitable household appliance. It should be understood that thepresent disclosure is not limited to washing machine appliances 100, andthat any suitable appliance having a control panel is within the scopeand spirit of the present disclosure.

FIG. 1 is a perspective view of an exemplary washing machine appliance100. As illustrated, washing machine appliance 100 generally defines avertical direction V, a lateral direction L, and a transverse directionT, each of which is mutually perpendicular, such that an orthogonalcoordinate system is generally defined. Washing machine appliance 100includes a cabinet 102 that extends between a top 104 and a bottom 106along the vertical direction V, between a left side 108 and a right side110 along the lateral direction L, and between a front 112 and a rear114 along the transverse direction T.

As illustrated for example in FIG. 1, cabinet 102 includes a front panel130 with a door 134 rotatably mounted to front panel 130. Door 134includes a handle (not shown) that, e.g., a user may pull when openingand closing door 134. Further, although door 134 is illustrated asmounted to front panel 130, it should be appreciated that door 134 maybe mounted to another side of cabinet 102 or any other suitable supportaccording to alternative embodiments.

A control panel 160 is coupled to front panel 130. Control panel 160defines an outer surface 162. The control panel 160 and outer surface162 may be part of a user interface for operator selection of machinecycles and features. As one example of such user interface, the controlpanel 160 may be used as part of a capacitive touch sensing system toallow for the selective activation, adjustment, or control of thewashing machine appliance 100. In such embodiments, the control panel160 may include a dielectric panel of the capacitive touch systemwhereby the capacitive touch system registers touches on the outersurface 162. The user interface may also provide for the selectiveactivation, adjustment, or control of any timer features or otheruser-adjustable inputs. One or more of a variety of electrical,mechanical or electromechanical input devices including rotary dials,push buttons, toggle/rocker switches, and/or touch pads can also be usedin combination with the capacitive touch input components. Control panel160 may also include a display component, such as a digital or analogdisplay device designed to provide operational feedback to a user.

Also, although described with respect to washing machine appliance 100,it should be readily understood that a user interface as describedherein could be used with any suitable appliance. Examples of such otherappliances include but are not limited to: dryer appliances, cookingappliances, and/or refrigerator appliances. Panel 160 may be constructedof glass, ceramics, plastics, and/or combinations thereof. Suitableplastic materials may include acrylics, polyethylene terephthalate(“PET”), or the like. In some embodiments, a touch screen may beincorporated into or may form the control panel of an appliance; forexample, the touch screen or control panel may be incorporated into abacksplash of a cooktop or dryer appliance.

Operation of washing machine appliance 100 can be regulated by acontroller 166 that is operatively coupled, i.e., in communication with,control panel 160. By way of example, the controller may include amemory and one or more processing devices such as microprocessors, CPUsor the like, such as general or special purpose microprocessors operableto execute programming instructions or micro-control code associatedwith operation of appliance 100. The memory may represent random accessmemory such as DRAM, or read only memory such as ROM or FLASH. Thememory may be a separate component from the processor or may be includedonboard within the processor. In one embodiment, the processor executesprogramming instructions stored in memory.

The controller 166 may be positioned in a variety of locationsthroughout washing machine appliance 100. In the illustrated embodiment,e.g., as shown in FIG. 1, the controller 166 may be located under ornext to the control panel 160. In such an embodiment, input/output(“I/O”) signals are routed between the controller and variousoperational components of appliance 100 such as control panel 160,sensors, graphical displays, and/or one or more alarms. In oneembodiment, the control panel 160 may represent a general purpose I/O(“GPIO”) device or functional block. Control panel 160 may be incommunication with the controller 166 via a direct connection, e.g.,without intervening cables or terminations. A user of washing machineappliance 100 may input and receive information regarding the operationof washing machine 100 at control panel 160. A variety of text, digits,and/or symbols may be printed on control panel 160. In some embodiments,no text, digits, or symbols may appear on control panel 160 unlesswashing machine appliance 100 is in use.

Turning now to FIG. 2, the appliance 100 may include a control module164. The control module 164 may include part or all of the control panel160 and may provide a robust connection of at least part of the controlpanel 160 with the controller 166. For example, some or all of theabove-described components of the controller 166 may be provided on aprinted circuit board (PCB) 202 of the control module 164. In someembodiments, the control module 164 may include a film 200 havingconductive ink 206 embedded in the film 200. A header 204 may beprovided in the film 200 for directly mounting the film 200 to theprinted circuit board 202, e.g., without the use of a separate cable orother connector and associated terminals. When the film 200 is directlymounted to the printed circuit board 202 via the header 204, anelectrical connection is thereby established such that the printedcircuit board 202 (e.g., including a controller 166 thereon) is inoperative communication with the conductive ink 206 embedded in the film200.

In some embodiments, the control panel 160 may include a capacitivetouch sensor, whereby appliance 100 is controlled at least in partthrough touch inputs on control panel 160, and more particularly onouter surface 162 thereof, by a user of the appliance 100. In suchembodiments, the outer surface 162 may be defined by the film 200 or anadditional panel, e.g., of plastic or glass or other translucentmaterial, may be provided. The capacitive touch sensor may include oneor more capacitive components, e.g., touch areas 207, formed of theconductive ink 206 embedded in the film 200. The capacitance of thetouch sensor(s) 207 of the control panel 160, in particular changes inthe capacitance, may be measured and/or monitored by the controller 166to detect a touch input from a user. For example, the controller 166 onthe printed circuit board 202 may be in communication with the touchsensors 207 formed of conductive ink 206 in the film 200 by a directconnection between the film 200 and the printed circuit board 202, asdescribed in more detail below.

As shown in FIG. 2, the control module 164 may include a housing 300.The housing 300 may include a top portion 306 with an outer surface 308at an outermost extent of the top portion 306. FIG. 2 provides anexploded view of the control module 164 for illustrative purposes only.In at least some embodiments, the components of the control module 164,in particular the housing 300 and the film 200, may be integrallyjoined. For example, the conductive ink 206 may be applied to the film200 by printing methods which are generally understood in the art. Thefilm 200 including the conductive ink 206 therein may be in-molded intothe housing 300 of the control module 164 which is molded of a suitableplastic material. Such in-molding may include forming the housing 300 ina mold with the film 200 placed in the mold prior to flowing the plasticmaterial into the mold. Accordingly, the header 204 of the film 200 willbe embedded into and integrally molded into the housing 300, e.g.,generally at a header portion 304 of the housing 300, as indicated inFIG. 2.

As may be seen in FIG. 3, the film 200 may be integrally molded onto theouter surface 308 of the top portion 306 of the housing 300. The header204 may be in contact with and in electrical communication with theconductive ink 206 embedded in the film 200, e.g., including capacitivetouch areas 207 formed of the conductive ink 206. As a result of thein-molding process described above, the housing 300 is formed with theheader 204 of the film 200 integrally molded into and extending throughthe top portion 306 of the housing 300, e.g., at the header portion 304.Thus, the printed circuit board 202 may be installed in the housing 300and directly connected to the film 200 via the header 204, such as witha solder joint 220, as illustrated in FIG. 3.

As shown in FIG. 3, the printed circuit board 202 may be mounted withinthe housing 300 proximate an inner surface 310 of the top portion 306 ofthe housing 300. In some embodiments, the top portion 306 of the housing300 may include one or more light guide apertures 302 extending throughthe top portion 306 of the housing 300 from the inner surface 310 to theouter surface 308. In such embodiments, the control module 164 may alsoinclude one or more light emitting diodes (LEDs) 226 on the printedcircuit board 202, the number of LEDs 226 corresponding to the number oflight guide apertures 302. As illustrated in FIG. 3, the LEDs 226 arecorrespondingly located on the printed circuit board 202 such that eachLED 226 is positioned generally within or proximate to a correspondinglight guide aperture 302. For example, the LEDs 226 are positioned on asurface of the printed circuit board 202 proximate to and facing theinner surface 310 of the top portion 306 of the housing 300, and each ofthe LEDs 226 extends from the printed circuit board 202 into or towardsa corresponding one of the light guide apertures 302. Thus, as shown,each LED 226 may be aligned with the corresponding light guide aperture302 and a corresponding user input, e.g., touch area 207, defined by theconductive ink 206. Accordingly, in some embodiments, the control module164 of the appliance 100 may include center-lit capacitive touchsensors, such as the touch areas 207 illustrated in FIG. 3, which arecenter-lit by the corresponding LED 226 via the corresponding lightguide aperture 302. In the illustrated embodiment of FIG. 3, the LEDs226 are generally centered in the light guide apertures 302. In variousother embodiments, the LEDs 226 may be aligned with the light guideapertures 302 in any suitable alignment to provide illumination to acenter of one or more corresponding user inputs, such as buttons or theillustrated touch areas 207. For example, in some embodiments, the toucharea 207 may be offset from the LED 226, such that the light guideaperture 302 extends obliquely between the touch area 207 and the LED226, and the LED 226 may be aligned with the light guide aperture 302such that the LED 226 emits light into the light guide aperture 302 at adesired angle whereby the light guide aperture 302 may direct the lightfrom the LED 226 to the desired portion, e.g., center, of the touch area207. Additionally, the top portion 306 of the housing 300 may includecontinuous opaque material between the light guide apertures 302, suchthat light from the LEDs 226 is not transmitted to areas of the film 200outside of the touch areas 207.

FIGS. 4-6 illustrate various example embodiments of direct mounting theheader 204 of the film 200 to the printed circuit board 202. The housing300 is omitted from the illustrations of FIGS. 4-6 solely for simplicityand clarity. As generally shown in FIGS. 2-6, the header 204 may includeone or more pins 208 and the printed circuit board 202 may include acorresponding number of thru holes 214 to directly receive the pins 208.In such embodiments, the film 200 may be directly mounted to the printedcircuit board 202 by the pin 208 and the thru hole 214, for example withthe pin 208 soldered into the thru hole 214 of the printed circuit board202, as illustrated in FIG. 3, where the solder joint is indicated by220. In various embodiments, the pin 208 may include a base portion 210and an elongate portion 212 extending from the base portion 210. Thebase portion 210 may be in direct contact with the film 200 and theelongate portion 212 may extend from the base portion 210 and away fromthe film 200. For example, the elongate portion 212 of the pin 208 mayextend towards the printed circuit board 202, e.g., to and through thethru hole 214 in the printed circuit board 202, as shown in FIGS. 4-6.In various embodiments, at least the base portion 210 of the pin 208 maybe integrated into the film 200.

As shown in FIG. 4, the pin 208 may be adhered to the film 200 with aconductive adhesive 216 and sealed to the film 200. For example, the pin208, e.g., the base portion 210 thereof, may be sealed to the film 200with an additional layer 218 of film material. As another example, asillustrated in FIG. 5, the base portion 210 may be embedded in the film200. In yet another example, the pin 208 may be crimped to the film 200,e.g., as illustrated in FIG. 6.

As shown in FIGS. 7 and 8, in some embodiments the film 200 may besurface mounted to the printed circuit board 202 by joining a conductivesurface on the film 200 to a conductive surface on the printed circuitboard 202. For example, the header 204 may include a solder pad 222 onthe film 200. For example, the conductive ink 206 may be a solderableink, such as a carbon-type solderable conductive ink. In suchembodiments, the solder pad 222 may be provided as an exposed portion ofthe conductive ink 206. The printed circuit board 202 may include asolder pad 224 thereon. The solder pads 222 and 224 each comprise aconductive material, thus each of the solder pads 222 and 224 provides aconductive surface on each of the film 200 and the printed circuit board202, respectively. Thus, the film 200 may be directly mounted to theprinted circuit board 202 with a conductive surface to conductivesurface bonded interface, e.g., by soldering the exposed portion 222 ofthe conductive ink 206 to the solder pad 224 on the printed circuitboard 202.

It should be understood that the descriptions herein of an appliance arebut one example of a possible field of use for the control module.

This written description uses examples to disclose the technology,including the best mode, and also to enable any person skilled in theart to practice the technology, including making and using any devicesor systems and performing any incorporated methods. The patentable scopeof the technology is defined by the claims, and may include otherexamples that occur to those skilled in the art. Such other examples areintended to be within the scope of the claims if they include structuralelements that do not differ from the literal language of the claims, orif they include equivalent structural elements with insubstantialdifferences from the literal languages of the claims.

What is claimed is:
 1. An appliance defining a vertical direction, alateral direction and a transverse direction that are mutuallyperpendicular to one another, the appliance comprising: a cabinetextending between a top and a bottom along the vertical direction,between a left side and a right side along the lateral direction, andbetween a front and a rear along the transverse direction; and a controlmodule disposed in the cabinet, the control module comprising: a housinghaving a film integrally molded onto an outer surface of the housing,the film comprising conductive ink embedded in the film; a header on thefilm in electrical communication with the conductive ink embedded in thefilm; and a printed circuit board mounted within the housing proximatean inner surface of the housing, the film connected to the printedcircuit board via the header, whereby the printed circuit board is inoperative communication with the conductive ink embedded in the film. 2.The appliance of claim 1, wherein the conductive ink in the film definesat least one touch area of a capacitive touch sensor.
 3. The applianceof claim 1, the housing comprises a light guide aperture extendingthrough the housing from the inner surface to the outer surface.
 4. Theappliance of claim 3, further comprising an LED on the printed circuitboard, wherein the LED is aligned with the light guide aperture and auser input defined by the conductive ink.
 5. The appliance of claim 1,wherein the header comprises a pin, the printed circuit board includes athru hole, and the film is directly mounted to the printed circuit boardby the pin and the thru hole.
 6. The appliance of claim 5, wherein thepin is conductively adhered to the film and sealed to the film.
 7. Theappliance of claim 5, wherein the pin comprises an elongate portion anda base portion, the base portion embedded in the film.
 8. The applianceof claim 5, wherein the pin is crimped to the film.
 9. The appliance ofclaim 5, wherein the pin is soldered into the thru hole of the printedcircuit board.
 10. A control module of an appliance, the control modulecomprising: a housing having a film integrally molded onto an outersurface of the housing, the film comprising conductive ink embedded inthe film; a header on the film in electrical communication with theconductive ink embedded in the film; and a printed circuit board mountedwithin the housing proximate an inner surface of the housing, the filmconnected to the printed circuit board via the header, whereby theprinted circuit board is in operative communication with the conductiveink embedded in the film.
 11. The control module of claim 10, whereinthe conductive ink in the film defines at least one touch area of acapacitive touch sensor.
 12. The control module of claim 10, wherein thehousing comprises a light guide aperture extending through the housingfrom the inner surface to the outer surface.
 13. The control module ofclaim 12, further comprising an LED on the printed circuit board,wherein the LED is aligned with the light guide aperture and a userinput defined by the conductive ink.
 14. The control module of claim 10,wherein the header comprises a pin, the printed circuit board includes athru hole, and the film is mounted to the printed circuit board by thepin and the thru hole.
 15. The control module of claim 14, wherein thepin is conductively adhered to the film and sealed to the film.
 16. Thecontrol module of claim 14, wherein the pin comprises an elongateportion and a base portion, the base portion embedded in the film. 17.The control module of claim 14, wherein the pin is crimped to the film.18. The control module of claim 14, wherein the pin is soldered into thethru hole of the printed circuit board.